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Old 02-14-2018, 02:55 PM
dwmh dwmh is offline
MetalShaper of the Month May 2018, July 2022
Join Date: Aug 2015
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Default Lucas P100 style replica headlamp

I wanted a small quick project to exercise my wheeling, aluminium welding, and metal finishing. I decided to make LED lamp of similar size and shape to the 12" P100 headlamp as used on Bentleys, Rolls, Jags etc. I found a plastic mixing bowl was close to the shape and size needed, which saved making a buck. I made it in three main segments, all shaped just by stretching on the wheel. These were gas welded together.
The welds were filed then run through the English wheel to level them. I then shaped an end cap which was welded on.
















The final part was to roll a step on the edge with the bead roller for the bezel. This also needed shrinking with the Lancaster.

I made a former for the bezel and shaped it in the bead roller and Pullmax type machine before welding it at the joint.




Next was metal finishing and quick polish (it needs more) before assembly with an LED bulb and fitting over a workbench. It is just the right height to hit my head on when I sit down!!!!






David Hamer

Last edited by dwmh; 02-15-2018 at 02:31 PM. Reason: spelling mistake
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Old 02-14-2018, 04:34 PM
cliffrod cliffrod is offline
MetalShaper of the Month January 2020, March 2022
Join Date: Dec 2014
Location: Spartanburg, SC
Posts: 2,707

Looks great. I like seeing the old lamp look preserved. The tri-bar detail of these lights is so iconic. Will the housings be left polished or painted after they are metal finished?
AC Button II Carolina Sculpture Studio Channel
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Old 02-14-2018, 04:49 PM
Gareth Davies Gareth Davies is offline
Join Date: Aug 2012
Location: Staffordshire, England
Posts: 661

Nice work David.
Gareth Davies
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Old 02-14-2018, 05:26 PM
Charlie Myres Charlie Myres is offline
Join Date: Jun 2013
Location: Narrogin, Western Australia
Posts: 505

Great idea and a wonderful project, well done!

Cheers Charlie
Why does dust stick to everything, but nothing sticks to dust?
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Old 02-14-2018, 05:38 PM
Fordor Fordor is offline
Join Date: Jul 2013
Location: Saranac, Michigan
Posts: 10

Nice project. Love seeing pictorial projects . They inspire me to try different things.
Robert Livingston
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Old 02-14-2018, 08:17 PM
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Gojeep Gojeep is offline
MetalShaper of the Month March 2015, March 2020,, June 2022
Join Date: Nov 2013
Location: Eastern Melbourne, Australia
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That is a great little project.
aka. Gojeep
Victoria, Australia

Invention is a combination of brains and materials.
The more brains you use, the less materials you need.
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Old 02-15-2018, 11:57 AM
Jim Tomczyk Jim Tomczyk is offline
Join Date: Feb 2013
Location: England,UK
Posts: 69

Nice work David, looks the business and much more satisfying than buying one.What tooling did you use on the vibroshear to form the bezel?

"I have not Failed - I've just found 10,000 ways that have not worked" - Thomas Edison
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Old 02-15-2018, 02:28 PM
dwmh dwmh is offline
MetalShaper of the Month May 2018, July 2022
Join Date: Aug 2015
Location: Nr Oxford UK
Posts: 530

Thanks all for kind words.
I did the post to show that a small quick project could test a few skills. My intention is to leave it metal finished. My previous project was an aluminium hardtop for my E-type Jag, but I soon realised my metal finishing skills were lacking, so I wanted something a LOT smaller to refine them on.

Jim well spotted that my Pullmax type machine is a Vibroshear, I needed to roll the flange round where the bezel meets and holds the glass (polycarbonate) in. I used a male upper that I normally use as a linear stretching die and for the female bottom I used a delrin block with a hollow of the matching shape. The shape was put in with a dremel and a crosscut burr, which breezed through it.
Am I right in thinking that you now own Gareth's Vibroshear?

All the shape for the main body was done on the wheel, by luck I could reach everywhere with the wheel.

The inside could do with tidying up to hide the wiring but with Spring in the air my motorcycle isn't going to ride itself.

David Hamer
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Old 02-16-2018, 09:24 PM
Oldnek Oldnek is offline
Join Date: Mar 2011
Location: Ulladulla, Australia
Posts: 1,346

Nice Job David.
EK Holden V8
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Old 04-30-2018, 10:19 PM
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neilb neilb is offline
MetalShaper of the Month March 2019
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Location: Melbourne OZ
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congrats on MSOTM david
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